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  1. #1

    Need help with 96 750 sts, very lost.

    Ok I purchased a 96 Kawasaki 750 STS and am having some issues. 1st Issue---motor starts and idles and will go for a couple of seconds at WOT then start to surge between 5 and 7500 RPMs or somewhere in there. You can hit the choke and it will get up and go for about 2 seconds and get back to the surge as it seems to struggle for gas. Sounds like fuel so I took it back to the garage and checked ignition, compression and drained old gas. Compression was about 130 on both and had good spark gap on gap tester. Felt like it was just a carb/fuel pump problem so I purchased a kit and rebuilt carb. Carb was clean but I rebuilt it anyway and started looking for air leaks between the tank and carb. Found the gasket on the fuel cap had a bad seal so replaced it. Soaped the rest of the hoses and found no leaks as I blew into the return line to pressurize the tank. Still surges. 2nd Issue---During my inspection and having my head down by the motor found an oil line with a knot in it not attached to anything. Hoping that it just fell off during my rooting around I looked for where to attach. Maybe an air leak is the nipple for the oil hose? Cannot find where it goes. Went to ebay and got the factory manual for my ski and it shows only 1 nipple off the oil pump going to the manifold under the single carb. My oil pump has 2 nipples and hoses, one is already going to the manifold. So back to the internet and look up an illustrated parts breakdown for a 96 sts and it shows 2 carbs with 2 tubes coming off the oil pump attaching to the carbs. I only have 1 carb. Anyone got an idea? Thanks in advance Skippy!!!


  2. #2
    steve45's Avatar
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    Welcome aboard, Skippy!

    Only one carb? Somebody has swapped engines with an older 'Ski. The original engine had two carbs and a line going to each carb.

    Did you see any water in the carbs? It's possible that the bad gas cap seal may have let some water into the tank. Also, check the gas cap for cracks, most of my 750s had cracked caps. I replaced them with billet caps.

  3. #3
    Yes only one carb. The motor does have a serial number on it, is there a place on line to reference that number? No water in the carb or gas I pulled from the ski but still drained the tank in case it was stale. I also replaced the cap, it was cracked. The more I looked at it the more it looks Frankensteined. The way the throttle cable attaches to the single carb appears to be at an odd angle and the choke cable has been jury rigged.

  4. #4
    steve45's Avatar
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    There are filters on the fuel pickups inside the tank. I'd suggest you pull those and have a look. I removed mine and put rubber hoses on the pickup tubes to get the length right, then I installed an inline filter. I think some of them came with inline filters. No reason to have two filters 3 feet apart.

  5. #5
    Well pulled out the fuel pickup on the tank and it about fell apart on me. The tubes looked cracked/very corroded (probably pinholes) and the filters were pretty much toast (fell apart as I tried to take them off. Actual surprised I did not find bits of them in the carb when I cleaned it. Found a NOS on Ebay and ordered. Also blew thru the tank vent ck valve and could blow both ways so It's bad as well and on order. Hopefully you will hear good things when I get the parts in. Thanks for the advice Steve45.

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